Differential speed shafted machines and uses therefor, including discontinuous and continuous side by side bonding

ABSTRACT

An apparatus having independently rotating shafts for producing discontinuous and continuous side by side bonding using independently rotating bonding units.

RELATED APPLICATIONS

This application claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 61/510,192, filed 21 Jul. 2011.

BACKGROUND OF THE INVENTION

The present invention relates to disposable undergarments and, more specifically, to methods and apparatuses for forming disposable undergarments, and particularly to removing unwanted portions of web material such as leg holes, from the undergarment as it is formed.

Generally, disposable undergarments such as pants-type diapers are made up of two nonwoven layers of material with elastic strands of material placed between the two nonwoven layers of material thus creating an elastic web laminate. The layers of material are continuous sheets of material that are eventually cut into individual undergarment lengths. The elastic strands may be arranged and cut so that specific areas of the undergarment are free of elastic tension or forces. An absorbent pad, often contained within an insert or core is then also placed into the pants-type diaper product.

To insure the pants-type diaper retains a proper shape and to hold all of the added layers of the diaper, reinforcing layers and backing materials are normally added to the continuous sheets of material, with the reinforcing layers corresponding to the cut elastic strands of each individual blank. Each of these layers needs to be adhesively joined at some point in the manufacturing process to the elastic web laminate to form the completed undergarment.

Often, void spaces need to be created in the diaper, such as holes cut out of the main web for provided leg holes when the undergarment is ultimately formed. To create the void spaces, the web is ordinarily die cut, with the web severed between a die and an anvil. The portion of the web material that is removed is referred to as a “chip.” As the die wears throughout time, the severing of the chip from the web material becomes gradually a duller cut. This complicates the removal of the chip because the severing might not create a continuous cut out chip, with possibly some strands of the web material still coupling the chip with the web. It is desired to lengthen the amount of time and increase the number of chips that a single die can effectively be used for, to reduce the number of die change-outs.

SUMMARY OF THE INVENTION

A system for removing chips from a web is disclosed, the system comprising a rotationally variable speed shoe for receiving a chip, a rotationally constant speed transfer roll for receiving a portion of a web from a die and anvil system, said shoe initially rotating at said constant speed, next slowing in rotational speed to allow said portion of said web to rip away from said chip at a leading rotational edge of said chip, next increasing in rotational speed to allow said chip to rip away from said web at a trailing rotational edge of said chip.

Another embodiment of the present invention is the use of an apparatus for producing discontinuous and continuous side by side bonding using independently rotating bonding units.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a trim shoe of the present invention, with an infeed web, and a chip to be removed therefrom.

FIG. 2 is a two dimensional representation of the trim shoe of FIG. 1.

FIG. 3 is a cross sectional view of a trim shoe.

FIG. 4 is a schematic view of a trim shoe receiving an article from a transfer roll in an initial chip engaging position.

FIG. 5 is a schematic view of the trim shoe separating a first article from a second article.

FIG. 6 is a schematic view of the trim shoe separating trim from the first article.

FIG. 7 is a schematic view of the trim shoe discharging the trim.

FIG. 8 is a schematic view of the trim shoe returning to its initial chip engaging position.

FIG. 9 is a schematic view of the trim shoe returned to its initial chip engaging position.

FIGS. 10-13 are plan views of the position of the chip relative to the web, demonstrating the ripping effects of the present invention.

FIG. 14 is a perspective view of a diaper with discontinuous and continuous side by side bonding;

FIG. 15 is an apparatus for producing discontinuous and continuous side by side bonding using independently rotating bonding units;

FIG. 16 is a cross sectional view of an apparatus for producing discontinuous and continuous side by side bonding using independently rotating bonding units;

FIG. 17 a-c, and FIG. 18 a-c are side views, with portions broken away, of sequences of operation of an apparatus for producing discontinuous and continuous side by side bonding using independently rotating bonding units;

FIG. 19 is a chart showing time and speed, and velocity profiles of the rotating units of the apparatus for producing discontinuous and continuous side by side bonding using independently rotating bonding units.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

Referring now to FIG. 1 a perspective view of a trim removal system 10 of the present invention is shown. An infeed web 24, and a chip or chips 30 to be removed therefrom is shown. A transfer roll 14 and an associated trim shoe or trim shoes 12 are provided to engage the web 24 and chips 30. Preferably, the trim shoes 12 are shaped complimentary with the chips 30. Vacuum ports 16 are provided on the transfer roll 14 and trim shoes 12 for maintaining the web 24 and chips 30 in close contact with the transfer roll 14 and trim shoes 12.

An inner axle 18 and an outer axle 20 are coupled to the transfer roll 14 (or hub 22) and the trim shoes 12, respectively. The inner axle 18 and the outer axle 20 are capable of being operated at different speeds in relation to one another by servo motor (not shown). This difference in speed allows the trim shoes 12 to rotate faster or slower with respect to the transfer roll 14 as desired. In use, as will be described later, this speed differential creates a ripping effect by first pulling the web 24 away from the chip 30 as the transfer roll 14 is rotating faster than the shoe 12, then by pulling the chip 30 away from the web 24 as the shoe 12 is rotating faster than the transfer roll 14.

Referring now to FIG. 2, a two dimensional representation of the trim shoe 12 and transfer roll 14 of FIG. 1 is shown. As can be seen, vacuum channels 17 communicate with vacuum ports 16 on both the trim shoe 12 and transfer roll 14 to maintain control of the chip 30 and web 24. From this perspective, it can be seen that different rotational speeds of the trim shoe 12 and transfer roll 14 will cause a ripping effect by first pulling the web 24 away from the chip 30 as the transfer roll 14 is rotating faster than the shoe 12, then by pulling the chip 30 away from the web 24 as the shoe 12 is rotating faster than the transfer roll 14.

FIG. 3 is a cross sectional view of a trim shoe 12 and transfer roll 14 of the present invention. As can be seen, vacuum is communicated to ports 16 through channels 17, which are coupled to a source of vacuum (not shown). Rotation of the outer axle 20, which is coupled to the shoe 12, causes rotation of the shoe 12. The inner axle 18 is coupled preferably to hub 22 and to transfer roll 14.

Referring now to FIGS. 4-9, a sequence is shown of the trim removal system 10 removing chips 30 and discharging them, and then the system 10 returning to its initial position to remove more chips 30 from the next segment of web 24. FIGS. 10-13 are plan views of the position of the chips 30 relative to the web 24 at the positions associated with FIGS. 4-7 respectively, demonstrating the ripping effects of the present invention.

Referring now to FIG. 4, a schematic view of the system 10 is shown receiving an infeed web 24. In this figure, die and anvil system 26 is shown rotating to engage the web 24 and cut from it chips 30 (not apparent in this view), as is well known in the art. Unfortunately, the die of the die and anvil system 26 is susceptible to wear and tear and requires replacement once the die dulls to an unacceptable condition.

In this view, the trim shoe 12 can be seen in an initial chip engaging position, aligned to receive the chip 30 of the web 24 onto the shoe 12, which, as described previously, will be urged against the surface of the shoe 12 by vacuum ports 16. The trim shoe 12 will be seen to be rotating about outer axis 20. In this view, a discharge chute 28 is shown for ultimately receiving waste chips 30, and an outfeed conveyor 40 is provided for receiving the web 24 with the chip 30 removed, for further processing and manufacturing steps in the composition of the disposable garments, as desired.

Inner axle 18 is preferably operated at a first continuous speed, rotating hub 22 and transfer roll 14 at a continuous speed, consistent with the infeed speed of the web 24. At this initial chip engaging position shown in FIG. 4, the outer axle 20, and associated shoes 12, are rotated at the same speed as the inner axle 18.

The position of the chip 30 relative to the web 24 is shown in FIG. 10 for the initial chip engaging position. In this position, the anvil and die 26 has created a sever, but the chip 30 and web 24 could remain somewhat coupled depending on the sharpness of the die 26.

Referring now to FIG. 5, the outer axle 20, and associated shoes 12, are toggled slower than inner axle 18 to allow the web 24 to be ripped from the chip 30 at the leading edge of the chip 30 in the machine direction. It is apparent in this view that the distance between the trailing edge of the shoes 12 has become closer to the leading edge of the transfer roll 14.

This ripping is caused by the main web 24 being ripped away from the chip 30 at the leading edge of the chip 30 as is shown in associated FIG. 11.

Referring now to FIG. 6, the outer axle 20 is toggled equal to and then faster than the inner axle 18, to allow the chips 30 to rip from the web 24 at the trailing edge of the chips 30 as is shown in associated FIG. 12.

At this point in the process, the chip will be removed from the web 24 by ripping first the main web 24 away from the chip 30 at the leading edge of the chip 30, and next by ripping the trailing edge of the chip 30 from the web 24.

The outfeed conveyor 40 is provided for receiving the web 24 with the chip 30 removed as shown in FIG. 13, for further processing and manufacturing steps in the composition of the disposable garments, as desired. The vacuum of the transfer roll 14 can be turned off at this point to allow for release of the web 24 to the conveyor, for instance in accordance with application Ser. No. 11/141,552, entitled “High Speed Vacuum Porting” which is incorporated herein by reference.

Referring now to FIG. 7, the chip 30 is discharged into a discharge chute 28, which is preferably vacuum assisted, although other collection means would satisfactorily accomplish the function of collecting waste chips 30.

It is noted that vacuum is allowed to turn off of the shoes 12 to allow the chips 30 to release into the chute 28. Alternatively a vacuum in the chute 28 could simply be provided that is stronger than the vacuum applied to the shoes 12.

The rotational speed of the shoes 12 and outer axle 20, which were first operated at a speed roughly equal to inner axle 18, rotating hub 22 and transfer roll 14, initially decreased, or lagged as is shown by comparing FIG. 4 with FIG. 5.

Next, the rotational speed of the shoes 12 and outer axle 20, increased, or surged relative to the inner axle 18, rotating hub 22 and transfer roll 14.

In order to return to the initial chip engaging position, the rotational speed of the shoes 12 and outer axle 20, must again decrease, or lag relative to the inner axle 18, rotating hub 22 and transfer roll 14. This lag is apparent by comparing FIG. 6 to FIGS. 7, 8 and 9. Finally, in FIG. 9, through one revolution, the system 10 has removed and discharged the chips 30, discharged the web 24 for further processing, and the shoes 12 have been returned to their initial position to remove more chips 30 from the next segment of web 24.

Referring now to FIG. 14, another use for a machine with independently rotating shafts is shown. Namely, a diaper 100 with discontinuous bond 252 and continuous 254 side by side bondings can be produced.

Such bonds can be useful for bonding different portions, such as leg cuff portions of a diaper, at different intervals and spaces.

Referring now to FIG. 15, such an apparatus is shown, with a pair of continuous bonders 220 spaced apart from each other, but adjacent to intermittent and independently driven bonders 210. Shaft 240 drives the unit 210, while an independently driven chassis is coupled with bonding unit 220 (see FIG. 16).

Referring now to FIG. 17 a-c, and FIG. 18 a-c side views, with portions broken away, of sequences of operation of the apparatus 200 for producing discontinuous and continuous side by side bonding using independently rotating bonding units are shown. In FIG. 17 a, the continuous bonder 220 is creating (in conjunction with a cooperating ultrasonic unit, above the web, not shown), a continuous bond 254, while the intermittent bonder 210 is creating the intermittent bond 252. Through rotation of continuous bonder 220 at a speed of R1, and rotation of the independently driven speed R2 of the discontinuous bonder 210, a different spacing between discontinuous bonds can be produced according to the speed R2. The discontinuous bonder 210 loses contact with another cooperating ultrasonic unit above the web (not shown), causing no bond to be performed during that rotational period in the desired area. In FIG. 17C, it is seen that the discontinuous bonder 210 is again approaching the web at another desired location of bonding. In FIGS. 18A-18C, R4, the speed of the discontinuous bonder 210, is less than R3, the speed of the continuous bonder 220 and in this manner a similar bonding pattern can be achieved according to user preferences.

FIG. 19 is a chart showing time and speed, and velocity profiles of the rotating units of the apparatus for producing discontinuous and continuous side by side bonding using independently rotating bonding units as described with respect to FIG. 17 a-c, and FIG. 18 a-c.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 

We claim:
 1. An apparatus for creating at least two bond zones in a web processing operation, said apparatus comprising: a first rotating bonding element for creating a bond of web elements, said first rotating bonding element rotating at a rotational velocity matching a constant web velocity, said web elements traveling at said web velocity; a second rotating bonding element for intermittently creating a bond of web elements, said second bonding element rotating at a variable rotational velocity, said second rotating bonding element first rotating at a velocity different from said web velocity during a period of no bonding, second rotating bonding element next rotating at a velocity matching said web velocity during a period of bonding.
 2. An apparatus according to claim 1, the apparatus further comprising: a first shaft driving said first rotating bonding element; a second shaft driving said second rotating bonding element, said second shaft coaxial with said first shaft.
 3. An apparatus according to claim 1, said first rotating bonding element creating a continuous bond of web elements.
 4. An apparatus according to claim 1, said first rotating bonding element creating a continuous bond of web elements, said second rotating bonding element creating a discontinuous bond of web elements, said continuous bond of web elements and said discontinuous bond of web elements parallel to one another. 